Chambal Fertilisers and Chemicals Limited

G3AU Project
Magnetic Particle Examination Procedure
TEIPL Work No: 6341
Project Doc. No.: VD-M-U00-STA-PRC-BYFA003-000-0008 Page 01 of 08
LOI NO. : P / 6341 / 12991 / BYFA003

Vendor Work No: PV-506 & PV-507 Vendor Doc. No.: QCP/NDE/MT-01/506 Date: 03.10.2016

Chambal Fertilisers and Chemicals Limited

G3AU Project
Brown-Field Expansion Fertilizer Project
2200 MTPD Ammonia and 4000 MTPD Prilled Urea Plant
in Gadepan, Kota, Rajasthan (India)

Magnetic Particle Examination Procedure

FOR APPORVAL
AP APPROVED

AC APPROVED WITH COMMENTS

RE NOT APPROVED (Re-submit)

RV REVIEWED WITHOUT COMMENTS

RC REVIEWED WITH COMMENTS

NR NOT BE RETURNED

RETURN DATE 12/10/16

svc
PROJECT ORIGINATOR
RECEIVED DATE

System No. Equipment No. FWBS/AWBS

NA U-FA-3202 / 4202

01 Oct 3, 2016 For Approval Vashu Dev Vinod Kumar Vinod Kumar Vinod Kumar

00 Sep 16, 2016 For Approval Vashu Dev Vinod Kumar Vinod Kumar Vinod Kumar

DATE
REV ISSUE PURPOSE PREPARE CHECKED APPROVED AUTHORIZED
ISSUED

ISGEC HEAVY ENGINEERING LTD.

 Proc. No. : QCP/NDE/MT-01/506
MAGNETIC PARTICLE EXAMINATION Revision : 01
Date : 03.10.2016
PROCEDURE (YOKE TECHNIQUE)
Job. No. : PV-506 & PV-507
PED

1.0 PURPOSE AND SCOPE

This procedure covers the requirements of magnetic particle examination to detect and evaluate
discontinuities that are open to surface of Ferro-magnetic materials and welds of various shapes
and sizes as required by approved drawing using electro-magnetic yoke and dry visible (color
contrast) magnetic particles by true continuous method.

2.0 REFERENCE DOCUMENTS

2.1 ASME Sec VIII Div.-1 & 2, Edition-2015, ASME Sec V, Edition-2015, Approved ITP,
Drawings, ED-C00-STA-SPC-D-102 & MR No-PD-M-U00-STA-MRQ-BYFA003. 1

3.0* EQUIPMENT(S) AND EXAMINATION MEDIUM

3.1 EQUIPMENT TYPE = Electro-magnetic Yoke

MODEL = Y-7
MAKE = ITW Signode India Ltd.
RATED CAPACITY = 4.5 Kg
CURRENT TYPE = AC

3.1.1 The magnetizing power of yokes shall be verified prior to use each day the yoke is used and
whenever it has been subjected to major electric repair, periodic overhaul or damage. During
examination any increase in pole spacing from that used during calibration shall require
recalibration of the Yoke. The calibration shall be done as per procedure No. QCP/NDE/MT-03.

3.1.2 AC Magnetic Yoke shall have a lifting power of at least 10 lbs.(4.5 Kg) at the maximum pole
spacing that will be used.

3.1.3 Light meter shall be calibrated prior to its first use and at least once a year or whenever the meter
has been repaired. If meter has not been used for more than one year or more. Calibration shall be
done before being used.

3.2* The finely divided ferro-magnetic particles, dry visible (Grey) having particle size not more than
180 microns shall be used for examination. The color of particles shall provide adequate contrast
with the surface being examined. The inspection shall not be carried out if the surface
temperature of the part exceeds 300°C or as recommended by manufacturer of ferromagnetic
particles

MANUFACTURERS:
Magnaflux Magnetic gray particles manufactured by ITW Signode India Ltd shall be used.

4.0 QUALIFICATION OF PERSONNEL FOR EXAMINATION

4.1 The person employed for conducting examination, interpretation, evaluation, and calibrations
shall be qualified to Level II as per ISGEC’s written practice (QCP/NDE/01) for control and
administration of NDE personnel’s training, examination and certification, which complies with
the recommended practice SNT-TC-1A of ASNT.

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 Proc. No. : QCP/NDE/MT-01/506
MAGNETIC PARTICLE EXAMINATION Revision : 01
Date : 03.10.2016
PROCEDURE (YOKE TECHNIQUE)
Job. No. : PV-506 & PV-507
PED
5.0 METHOD

5.1* SURFACE PREPARATION: - Prior to examination the surface to be examined must be

checked visually, it shall be adequately smooth and may be in as fabricated condition. Surface
preparation by machining/grinding is necessary when surface irregularities could mask the
indications due to discontinuities.

5.2 PRE-TEST CLEANING: - All areas to be examined along with adjacent area within 25mm
min. shall be thoroughly cleaned with brush, organic solvents or grit blasting as applicable. The
area shall be free from scale, dirt, grease, and paint, welding flux, oil or any other foreign matter
that would interfere with the interpretation of the test.

5.2.2 Before the magnetic particle examination is conducted, a check of examination surface shall be
conducted to locate any discontinuity surface openings, which may not attract and hold magnetic
particles because of their width.

5.3* MAGNETIZATION TECHNIQUE: - Electromagnetic Yoke shall be used for producing

necessary magnetic flux in the area of part being examined. It is indirect magnetizing method.

5.3.1 At least two examination of each area shall be performed. During second examination line of
magnetic flux shall be perpendicular to those used during first examination.
A different technique for magnetization may be used for the second examination.

5.3.2 Examination shall be conducted with sufficient overlap (Minimum 15%) to ensure 100%
coverage.

5.4* APPLICATION OF DRY MAGNETIC PARTICLES: - Dry magnetic particles shall be

applied in such a manner that it should reach test part in a uniform cloud with a minimum of
force and form light uniform dirt like coating. Excess particles shall be removed by light stream
of air by bulb. During application and removal of excess particles magnetization current shall
remain on.

5.5* WHITE LIGHT INTENSITY: - White light intensity for examination with non-fluorescent
methods should be adequate at the surface of the part being examined. Light shall not be less than
1000 Lux on the test surface in any case. This can be achieved by holding an 24 Volts, 60 W
lamp with a reflector at 150 mm or 220 Volts 60 W lamp at 300 mm from the test surface.

5.6* MAGNETIC FIELD ADEQUACY AND DIRECTION: - Field indicators are not allowed to
be used to verify field adequacy. However to ensure availability of magnetic flux on a back
gouged/ground surface, a pie indicator may be used with the yoke technique.

5.7 SURFACE CONTRAST ENHANCEMENT: - The testing shall be done without use of any
surface contrast enhancement.

6.0 EVALUATION OF INDICATIONS

6.1 Discontinuities and defects will be indicated by retention of the magnetic particles. All such
indications are not necessarily defects. However, excessive surface roughness and magnetic
permeability variations (such as at the edge of heat affected zones) may produce similar

Page 3 of 8
 Proc. No. : QCP/NDE/MT-01/506
MAGNETIC PARTICLE EXAMINATION Revision : 01
Date : 03.10.2016
PROCEDURE (YOKE TECHNIQUE)
Job. No. : PV-506 & PV-507
PED
indications. If indications are believed to be non relevant, each type of indication shall be
explored to determine, if relevant linear discontinuities are present. An indication is the evidence
of a mechanical imperfection.

6.2 Relevant indications are as describe below;

a) Linear indications are those indications in which the length is more than three times the width.
Only indications with major dimensions greater that 1/16” (1.5 mm), shall be considered relevant.
b) Rounded indications or indications, which are circular or elliptical with the length less than three
times, the width.
c) Any questionable or doubtful indications shall be re-tested to verify whether or not actual defects
are present.
d) Localized surface imperfections, which may occur from machining marks, surface conditions, or
an incomplete bond between base metal and cladding, may produce similar indications, which are
not relevant to the detection of unacceptable discontinuities.

7.0 MARKING OF FLAWS

7.1 Where necessary, flaws shall be indicated by some appropriate means such as red wax pencil.

8.0 ACCEPTANCE STANDARDS

(Ref.: ASME Sec VIII div.1 Appendix-6)

All surfaces to be examined shall be free of:
8.1 Crack, Lack of fusion, Lack of Penetration, Undercuts.
a) Relevant linear indications more than 1.5 mm.
b) Relevant rounded indications greater than 5.0 mm.
c) Crack like indications detected, irrespective of surface conditions, are unacceptable.
d) Four or more rounded indication in a line separated by 1.5 mm or less edge to edge.

9.0 REPAIR REQUIREMENTS

9.1 Unacceptable imperfections shall be removed and re-examined to assure the complete removal.
Wherever a defect is removed and subsequent repair by welding is not required, the excavated
area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or
corners. Where welding is required after removal of a defect, the area shall be cleaned and
welded. Completed repairs shall be re-examined by the same method for detection of the defect
and by all other methods of examination that were originally required for the affected area, except
that, when the depth of repair is less than the radiographic sensitivity required, re-radiography
may be omitted.

9.2 Treatment of imperfections Interpreted Non-Relevant: - Re-examination by same method or

by other NDE method and/or by surface conditioning till such time that no defect is present.

10.0 POST EXAMINATION CLEANING

10.1 Post test cleaning is necessary where magnetic particle material(s) could interfere with
subsequent processing or with service requirements.
Employing the following method will perform post inspection cleaning.

Page 4 of 8
 Proc. No. : QCP/NDE/MT-01/506
MAGNETIC PARTICLE EXAMINATION Revision : 01
Date : 03.10.2016
PROCEDURE (YOKE TECHNIQUE)
Job. No. : PV-506 & PV-507
PED

a) The use of compressed air to blow off dry magnetic particles.

11.0 DEMAGNETIZATION

11.1 Demagnetization is required only if specified in the drawings, and shall be performed by any one
of the following methods:-
a) Withdrawal from alternating current coil.
b) Decreasing alternating current.
c) Reversing direct current.
d) Non Rejectable indication shall be recorded as specified in the referencing code section.
e) Rejectable indication shall be recorded as a minimum, the type of indication (linear or rounded),
location and extent (length or diameter).

12.0 REPORT

12.1 The final examination report shall be prepared in Inspection Request cum Report for Magnetic
Particle test.

Page 5 of 8
 Proc. No. : QCP/NDE/MT-01/506
MAGNETIC PARTICLE EXAMINATION Revision : 01
Date : 03.10.2016
PROCEDURE (YOKE TECHNIQUE)
Job. No. : PV-506 & PV-507
PED

13.0 Table 1 shows the Essential Variables as requirements of this procedure, Any change in
Essential Variable shall require revision and demonstration (As per T-150 of Article I) for re-
qualification of the procedure. Any other change shall require revision of the procedure.

Table-1 List of Variables

Sl. No. Essential Variable Reference

Para
1.0 Magnetizing Technique 5.3
2.0 Magnetizing current type or amperage outside range specified by 3.1
this procedure or as previously qualified
3.0 Surface preparation 5.1
4.0 Magnetic particles 3.2
5.0 Method of particle application 5.4
6.0 Method of excess particle removal 5.4
7.0 Minimum light intensity 5.5
8.0 Examination part surface temperature outside of the temperature 3.2
range recommended by the manufacturer of the particles or as
previously qualified
Abbreviation: ‘*’ = Essential Variable

Prepared by Reviewed and Approved by

Vashu Dev Vinod Kumar Singhi
(ASNT LEVEL-III-RT,UT,MT,PT,VT)
Cert. No.: 94482

Page 6 of 8
 Request No. : ___
REQUEST AND REPORT FOR MAGNETIC PARTICLE EXAMINATION
Date : _________
PED
To be filled in by shop
From: _____________________ To ___________________________

Job No./Client : _____________________ Surface Condition : _______________________ Inspection Authority : ______________

Material & Form : ______________ Stage of Testing : _____________________ Drg. No. : ________________________Rev. : ____
Mfd. Process : _____________________ Extent of MPT. : __________________ Code : : _____________________
S. No Part No. Seam No. Size ( Thickness Required) To be filled in by Inspection Engineer
All previous stages are cleared :
Visual Checked : Yes/ No
Items released for MPT : Yes / No
Remarks :

Sign. Shop Supervisor ___________________ Date _____________________ Sign. Inspection Engineer ________________ Date ______________
To be filled in by NDE Dept.
Procedure No. : _____________________________ Rev :____ Report No: ____________________
Technique : ___________________________________________ Overlap during Examination :_______

Equipment : _____________________ Suspension : _____________________

Observation :
Concentration : _____________________
Current : _____________________
Colour : _____________________
Particles : _____________________
Surface Temp : _____________________ Result :-
Medium : Dry /Wet
Demagnetisation: : ______________
Particle Application by: Blow/ Spray
Light equipment & intensity: 24 Volts 60 watt lamp
Excess Particle Removal : By light air Stream held at 150 mm from test surface( > 1000 Lux) Note : For indications detail (If any ) P.T.O.

Examined By : ________________________ Evaluation by : ___________________________ Witness / Review By AI /TP : _______

Name and Level :_____________________ I / II Name and Level :_____________________II / III Date : ______________
Date of Examination : _____________________ Date of Examination : ______________________
0902/1110 P.T.O
Page 7 of 8
OBSERVATON / EVALUAITON REPORT:-
SR. NO. TYPE OF INDICATON SIZE LOCATION FROM RESULT &
REFERENCE POINT REMARKS
1

10

11

12

Examined By (Level I/II) Evaluation By (Level II/III) Reviewed/Witnessed By TPI/AI

SIGNATURE

DATE
NAME
0902/1110

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